Right-Angle Electric Connector Housing Terminal Interface

Solution Overview

Problem

The assembly of right-angle electric connectors is cumbersome due to the need to insert wire ends through a housing opening and crimp the connector terminal, which can lead to improper mating and potential disconnection under tension.

Innovation Solution

The design includes a connector body with a wire opening and an insulator featuring a terminal guide and seat, allowing the terminal assembly to be easily inserted and seated, with a terminal lock to secure the assembly and prevent disconnection, facilitating coaxial alignment of the wire and terminal axes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the terminal assembly is inserted through the wire opening and crimped onto the wire, then the connection between wire and terminal is maintained, but the assembly process becomes cumbersome and complex

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The terminal guide is pre-formed as an integral part of the insulator, creating a prepared pathway that guides the terminal assembly into proper alignment with the wire opening before insertion occurs. This preliminary structural preparation eliminates the need for complex alignment operations during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The terminal guide acts as an intermediary structure between the wire opening and the terminal assembly. It provides a transitional pathway that mediates the insertion process, ensuring proper alignment and reducing assembly complexity by serving as a guiding interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the connector terminal is fixed inside the connector housing, then damage to the electric connector is prevented and proper mating is maintained, but the assembly process requires additional steps

Engineering Contradiction:

Improveconnector stabilityVSAvoidassembly steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The terminal guide is pre-formed as an integral part of the insulator structure, creating a prepared pathway that guides the terminal assembly into proper alignment with the wire opening before insertion occurs. This preliminary structural preparation eliminates the need for complex alignment operations during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The terminal guide acts as an intermediary structure between the wire opening and the terminal assembly. It provides a transitional pathway that mediates the insertion process, ensuring proper alignment and reducing assembly complexity by serving as a guiding interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the terminal assembly is easily inserted and seated, then the assembly process is simplified, but proper alignment and secure connection must be ensured

Engineering Contradiction:

Improveassembly easeVSAvoidalignment precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The terminal guide acts as an intermediary structure between the wire opening and the terminal assembly. It provides a transitional pathway that mediates the insertion process, ensuring proper alignment and reducing assembly complexity by serving as a guiding interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The terminal guide provides localized alignment features at the specific insertion point, concentrating the alignment function in a dedicated structural element rather than requiring precision throughout the entire connector housing. This localized approach maintains alignment precision while simplifying overall assembly.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9356378B1Electric connector housing with a terminal interface

Publication Date: 2016.05.31 LEAR CORP

AI summary

A method to assemble an electric connector includes inserting a terminal assembly with a wire attached thereto into a wire opening defined by a connector body. The terminal assembly is moved in an insertion direction to engage a terminal guide and is moved in a seat direction. The terminal assembly is moved further in the insertion direction to a seated position.